U.S. patent number 8,806,826 [Application Number 13/179,831] was granted by the patent office on 2014-08-19 for locking panel veneer system.
This patent grant is currently assigned to Matthew Mann. The grantee listed for this patent is Matthew Mann. Invention is credited to Matthew Mann.
United States Patent |
8,806,826 |
Mann |
August 19, 2014 |
Locking panel veneer system
Abstract
The present invention relates to the field of mortarless,
stone-like veneer systems for walls. More specifically, the present
invention relates to facade systems comprising a plurality of
panels with surfaces for engaging other panels in the system and
for resisting pullout of a panel once installed. Further provided
are facade systems comprising a plurality of panels which provide
stacked-stone corners for walls, columns, and posts when installed.
Preferred are systems comprising modular facade panels having (i) a
front face for forming part of a first facade, wherein the face is
formed as a plurality of stacked stones and has a concave
rectilinear polygonal outline configured for mating with adjacent
panels when installed in a facade system; (ii) a back side with a
suspension rail in communication therewith; and (iii) left and
right sides for forming part of another facade in an intersecting
plane. Such panel systems provide a seamless veneer with a strength
nearing that of mortar-based systems but having the ease of
installation provided by modular mortarless systems.
Inventors: |
Mann; Matthew (Peterstown,
WV) |
Applicant: |
Name |
City |
State |
Country |
Type |
Mann; Matthew |
Peterstown |
WV |
US |
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Assignee: |
Mann; Matthew (Peterstown,
WV)
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Family
ID: |
46454127 |
Appl.
No.: |
13/179,831 |
Filed: |
July 11, 2011 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20120174516 A1 |
Jul 12, 2012 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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61362740 |
Jul 9, 2010 |
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61486850 |
May 17, 2011 |
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Current U.S.
Class: |
52/475.1; 52/509;
52/478 |
Current CPC
Class: |
E04F
13/0873 (20130101); E04F 13/0805 (20130101); E04F
13/0816 (20130101); E04F 13/0733 (20130101); E04C
2003/0473 (20130101); E04F 2203/02 (20130101); E04F
2203/065 (20130101); E04C 2003/0434 (20130101) |
Current International
Class: |
E04C
2/38 (20060101) |
Field of
Search: |
;52/475.1,477,478,489.1,511,513,506.05,591.4 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Glessner; Brian
Assistant Examiner: Barlow; Adam
Attorney, Agent or Firm: New River Valley IP Law, PC
Mayberry; Michele L.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to and the benefit of the filing
date of U.S. Provisional Patent Application Nos. 61/362,740 and
61/486,850 filed respectively on Jul. 9, 2010 and May 17, 2011, the
disclosures of each of which are hereby incorporated by reference
herein in their entireties.
Claims
The invention claimed is:
1. A modular facade panel comprising: a front face for forming part
of a first facade, wherein the face is formed as a plurality of
stacked stones and wherein an outline of a front planar view of the
panel provides a concave rectilinear polygonal outline configured
for mating with adjacent panels when installed in a facade system;
a back side with a suspension rail in communication therewith; and
left and right sides for forming part of another facade in a
different plane; wherein the panel is configured such that, when a
plurality of panels are disposed as a facade to a concave corner, a
front of a first panel is capable of contacting a side of a second
panel and a front of the second panel is capable of contacting a
side of the first panel; and wherein the suspension rail of the
first panel comprises a first horizontal mounting bar and when
installed the first horizontal mounting bar overlaps a second
horizontal mounting bar of a suspension rail of the second panel
and is disposed between the second horizontal mounting bar and the
second panel; wherein the suspension rail of the first panel has a
configuration that is the same as that of the suspension rail of
the second panel.
2. The modular facade panel of claim 1, wherein the suspension rail
comprises an elongated planar member, an upper and lower mounting
bar, and means for receiving securing means for connecting the
suspension rail to a substrate surface.
3. The modular facade panel of claim 2, wherein the means for
receiving securing means of the suspension rail is an elongated
v-shaped groove disposed lengthwise below the upper mounting
bar.
4. The modular facade panel of claim 2, wherein the suspension rail
comprises means for flexing a mounting bar toward or away from the
planar member.
5. The modular facade panel of claim 2, wherein the suspension rail
further comprises feet disposed perpendicular to the elongated
planar surface and wherein the suspension rail is embedded in the
back side of the facade panel in a manner to provide an air gap
between the facade panel and the elongated planar member.
6. The modular facade panel of claim 1 comprising a top side
configured for engagement with a bottom side of another panel and
comprising a bottom side configured for engagement with the top
side of another panel when panels are installed.
7. The modular facade panel of claim 6, wherein the top side
comprises a protrusion with a surface recessed from the front face
of the panel and wherein the bottom side comprises a recess for
receiving the top protrusion of another panel.
8. A panel facade system comprising: a plurality of facade panels
each having a front face for forming part of a first facade,
wherein the face is formed as a plurality of stacked stones and an
outline of a front planar view of the panel provides a concave
rectilinear polygonal outline configured for mating with adjacent
panels when installed in the system; a back side with a suspension
rail in communication therewith; and left and right sides for
forming part of another facade in a different plane; wherein the
system is configured such that, when disposed as a facade to a
convex corner, a back of a first panel faces a side of a second
panel and a back of the second panel faces a side of the first
panel; and wherein the suspension rail of a first panel comprises a
first mounting bar and when installed the first mounting bar
overlaps a second mounting bar of a suspension rail of a second
panel, and the first mounting bar is disposed between the second
mounting bar and the second panel; and wherein the suspension rail
of the first panel has a configuration that is the same as that of
the suspension rail of the second panel.
9. The panel facade system of claim 8, wherein a group of the
plurality of panels is shaped to tessellate a surface that wraps
around a 270 degree corner or that wraps around a 90 degree corner
or both.
10. The panel facade system of claim 8 comprising at least three
different front face outlines chosen from z-shaped, t-shaped, and
inverted t-shape outlines.
11. The panel facade system of claim 10, wherein a group of the
plurality of panels is shaped to tessellate a surface disposed in
four planes.
12. A mortarless veneer system comprising: a plurality of panels
collectively comprising a facade for a surface, wherein one panel
face overlaps another panel face in the system; a suspension rail
operably connected with each panel for joining panels in the
facade, wherein each suspension rail comprises means for resisting
pull out of the panel from the facade disposed horizontally along
two opposing sides of the panel, and wherein the suspension rail of
a first panel comprises a first horizontal mounting bar and when
installed the first horizontal mounting bar overlaps a second
horizontal mounting bar of a suspension rail of a second panel and
is disposed between the second horizontal mounting bar and a back
of the second panel in a manner such that pull out of the second
panel from the facade causes the first and second horizontal
mounting bars to engage one another and resist the pull out;
wherein the suspension rail of the first panel has a configuration
that is the same as that of the suspension rail of the second
panel.
13. The veneer system of claim 12, wherein each panel and rail
together provide at least four planar surfaces for resisting pull
out of the panel from the facade and at least four additional
planar surfaces for resisting pull out of adjacent panels.
14. The veneer system of claim 13, wherein each panel has a stepped
surface configuration around its perimeter such that, upon
application of a pullout force applied to a panel two of the
stepped surfaces are capable of resisting removal of the panel by
engaging with two adjacent panels in the facade; and two of the
stepped surfaces provide pullout resistance for adjacent panels in
the facade.
15. The veneer system of claim 12, wherein in addition to the upper
and lower mounting bar of the suspension rail, each panel comprises
means for resisting its pull out from the facade disposed along two
adjacent sides of the panel.
16. The veneer system of claim 12, wherein in addition to the upper
and lower mounting bar of the suspension rail, each panel comprises
means for resisting pull out of an adjacent panel, which is
disposed along two adjacent sides of the panel.
17. The veneer system of claim 12, wherein in addition to the upper
and lower mounting bar of the suspension rail, each panel comprises
means for resisting its pull out from the facade disposed along two
adjacent sides of the panel and each panel comprises means for
resisting pull out of an adjacent panel disposed along two other
adjacent sides of the panel.
18. The veneer system of claim 17, wherein each panel has a stepped
top and bottom surface configuration which, when installed as a
facade and a central panel is surrounded on all sides by adjacent
panels in the facade, all of the adjacent panels are capable of
providing resistance to removal of the central panel due to the
configuration of the stepped surfaces and the suspension rail.
19. The mortarless veneer system of claim 12, wherein the second
horizontal mounting bar is disposed in a plane parallel to the back
of the second panel and the first horizontal mounting bar is angled
toward the first panel.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of mortarless,
stone-like veneer systems for walls. More specifically, the present
invention relates to facade systems comprising a plurality of
panels with surfaces for engaging other panels in the system and
for resisting pullout of a panel once installed. Further provided
are facade systems comprising a plurality of panels which provide
stacked-stone corners for walls, columns, and posts when installed.
Such panel systems provide a seamless veneer with a strength
nearing that of mortar-based systems but having the ease of
installation provided by modular mortarless systems.
2. Description of the Related Art
Conventional mortar-based facade systems, including brick and stone
are as difficult to remove as they are to install. Although the
strength of a mortar-based system is generally an advantageous
feature, such systems are susceptible to a number of disadvantages.
For example, installation of brick and stone using mortar requires
favorable weather and temperature conditions to be sure the mortar
sets properly. This limits installation, especially in areas where
seasonal changes occur, to relatively dry and ambient
conditions.
Another disadvantage to conventional stone and brick facade systems
is that such systems are labor intensive, messy, and time consuming
to install. Once mortar is mixed it must be applied within a
certain time period before it dries out and is no longer useable.
Often skilled contractors who have experience with stone and brick
are required to install the facade in an aesthetically pleasing
manner.
Mortar-based veneers are usually installed in a manner that leaves
no air space between the veneer and the wall to which it is
attached. Dry rot of the wall itself due to a lack of ventilation
is a common problem for such systems. Further, if moisture seeps in
behind the brick or stone veneer, mold, mildew, and deterioration
of the wall can develop increasing the chance of failure of the
veneer.
Buildings are known to settle for some time after construction,
leading to movement of walls. Typical mortar-based systems do not
allow or provide for very little allowance for such seismic
movement. Often times a mortar-based veneer will crack in response
to environmental changes and generally over time. Cracking allows
for moisture to seep into the system and provides an opportunity
for loosening of the stones or brick, which generally requires
replacement of the mortal to salvage the veneer, and which in turn
is typically an expensive endeavor.
In contrast, modular mortarless systems can be installed year round
regardless of external weather conditions. Likewise, modular
systems have the advantage of ease of installation, not requiring
special skills and so can be installed by a range of installers,
from the do-it-yourselfer to the trained stone mason. Even further,
mortarless systems because they do not have to be adhered to the
entire surface area of a wall can provide better ventilation and
moisture removal than conventional mortar-based veneers.
Existing mortarless systems, however, do not have the advantage of
strength to resist pullout of the modular panels. Modular
mortarless systems are usually configured for convenience of
manufacture at the expense of strength and aesthetic appeal. For
example, there is usually minimal overlap, if any, between the
panels of existing modular systems. With no overlap between the
tiles, it is relatively easy to insert a tool between the panels
and pry them away from the wall on which they are installed.
Likewise, with readily apparent joints or seams between panels, it
is usually instantly recognized that the system is a facade.
Compounding the issue is that for ease of manufacture the panels
are usually configured as a single universal shape panel. When
panels of the same size and shape are installed together in a
system it is typically quite easy upon visual inspection to
identify the outline of each panel.
What is desired is a facade that has the appearance and strength of
a stone and mortar installation, but which is cost effective to
manufacture and install. Ease of installation is also a plus
without compromising on aesthetic appeal. Thus, what is needed is a
modular, non-mortar system that addresses the disadvantages of
conventional mortar-based systems, but has the strength, ease of
installation, and aesthetic appeal of and aesthetic similarity to
these conventional systems.
SUMMARY OF THE INVENTION
Embodiments of the invention include, among other things, facade
systems, panels for facade systems, and brackets for hanging panels
in a system. In certain embodiments, the panels preferably comprise
one or more surfaces for engaging or overlapping other panels in
the system.
Facade panels of this invention encompass modular facade panels
comprising: (i) a front face for forming part of a first facade,
wherein the face is formed as a plurality of stacked stones and has
a concave rectilinear polygonal outline configured for mating with
adjacent panels when installed in a facade system; (ii) a back side
with a suspension rail in communication therewith; and (iii) left
and right sides for forming part of another facade in a different
plane.
Suspension rails according to embodiments of the invention can
comprise an elongated planar member, an upper and lower mounting
bar, and means for receiving securing means for connecting the
suspension rail to a substrate surface. Panels and facade system
embodiments of the invention need not comprise a suspension rail
with a particular configuration nor comprise all of these
functionalities, however, preferred embodiments include the
inventive suspension rails as well.
Receiving means for the securing means that is incorporated into
the suspension rail can be of any configuration. For example, the
suspension rail can comprise an elongated v-shaped groove disposed
lengthwise below the upper mounting bar for receiving screws at any
point along the width/length of the suspension rail. Holes, whether
circular or oblong, can alternatively be included to receive screws
and can be disposed at various point along the length of the
suspension rail.
Ideally, the suspension rail has some flexibility incorporated into
its structure or is comprised of a material that allows for flexing
or bending or one or both of the mounting bars. Such functionality
can include structure in the form of a c-shaped groove along the
length of the suspension rail to which the mounting bar is in
communication with. The c-shaped channel allows for the mounting
bar to be flexed toward or away from the body of the suspension
rail to allow for ease of insertion of the mounting bar into a
facade system on installation.
Feet for embedding or attaching the suspension rail to the back
side of a facade panel can also be incorporated into the suspension
rail. The feet can be disposed at any angle relative to the body of
the suspension rail, however, a perpendicular position is
preferred. Additionally, it is preferred to connect the panel with
the suspension rail in a manner to provide an air gap between the
facade panel and the elongated planar member. The air gap will
allow for any moisture that collects behind the panels to drain
away from the system and not interfere with the connection between
the panels and the wall surface after installation.
Panels according to the invention can also comprise additional
surfaces for engaging other panels of a facade system. For example,
the panels can comprise a top side or edge configured for
engagement with a bottom side or edge of another panel and can
comprise a bottom side configured for engagement with the top side
of another panel when panels are installed. This functionality can
be accomplished in a number of ways, but a suggested embodiment
includes incorporating a stepped surface into the top and bottom
sides of the panel that cooperate with respectively bottom and top
sides of adjacent panels. The stepped configuration at the top of
the panel results in a protrusion with a surface recessed from the
front face of the panel toward the wall, while at the bottom side
there is a recess for receiving the top protrusion of another
panel. Likewise, the protrusion formation can be incorporated into
the bottom edge of the panel, while the recess is incorporated into
the top. Similarly, these complementary protrusions and recesses
can be incorporated into any side of the panel for resisting pull
out of a panel from the wall once installed.
Specific embodiments of the present invention include facade
systems comprising a plurality of panels, wherein each panel is
operably configured to engage with other panels in the system on
all sides of the panel. For example, for a square or rectangular
tile, the tiles can be operably configured to engage on all four
sides of the square or rectangular shape of the tile.
Typically, the stones, tiles, panels, etc. will have a stepped
surface configuration for providing engaging surfaces. In
embodiments, the stepped surfaces will be capable of providing
engaging surfaces along the entire perimeter of the stone.
Preferred embodiments of the invention provide veneer systems,
wherein the panels comprise elongated engagement surfaces with a
total length of 50% or more of the perimeter of the panel. For
example, in a square type panel each of the elongated engagement
surfaces can comprise a length about equal to the length of one
side of the panel. Preferred embodiments include panels capable of
engaging 20%, 25%, 30%, 45%, 50%, 60%, 70%, 75%, 80%, 90%, 95%,
98%, or 100% based on length of the perimeter of the panel. Indeed,
any amount of engagement in the range of 25% to 100% of the length
of the perimeter is preferred.
Included in embodiments of the invention are veneer systems
comprising at least two universal brackets for providing support
against pullout of the panels. Each universal bracket (otherwise
referred to as a suspension rail) can provide a surface for
engaging another panel or for engaging with a corresponding bracket
of another panel. Preferably, each bracket comprises an engagement
surface substantially along the length of one side of the panel, or
a major part of the length thereof, such as 50% or more. The
brackets can also be configured to be a single piece providing one
or more, typically two, additional engagement surfaces. Preferably,
the bracket(s) are embedded in the panels during the manufacturing
process or prior to installation to provide easy to install panels.
The brackets, together with the length of the engagement surfaces
provided by the panels themselves, can provide a total engaging
length of 50% or more of the perimeter of the panel and up to 150%
of the perimeter, or any engagement length between. Preferably,
panels of the system with integral bracket(s) engage 100% to 150%
of perimeter length.
The features of novelty and various other advantages that
characterize the invention are pointed out with particularity in
the claims forming a part hereof. However, for a better
understanding of the invention, its advantages, and the objects
obtained by its use, reference should be made to the drawings that
form a further part hereof, and to the accompanying descriptive
matter, in that there is illustrated and described preferred
embodiments of the invention. The features and advantages of the
present invention will be apparent to those skilled in the art.
While numerous changes may be made by those skilled in the art,
such changes are within the spirit of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
These drawings illustrate certain aspects of some of the
embodiments of the present invention, and should not be used to
limit or define the invention.
FIG. 1 is a schematic drawing of a mortarless veneer system
according to an embodiment of the invention.
FIGS. 2A-E are respectively top and bottom planar views, a side
elevation view, and top and bottom perspective views of an
exemplary panel of the invention.
FIGS. 3A-C are respectively a side elevation view, a top planar
view, and a bottom perspective view of a hanging bracket embodiment
of the invention.
FIG. 4 is a representative post veneer system according to the
invention, which provides for seamless corners.
FIGS. 5A-B are front and back perspective views of a representative
first panel embodiment of the system illustrated in FIG. 4.
FIGS. 6A-B are front and back perspective views of a representative
second panel embodiment of the system illustrated in FIG. 4.
FIGS. 7A-B are front and back perspective views of a representative
third panel embodiment of the system illustrated in FIG. 4.
FIGS. 8A-B are front and back perspective views of a representative
fourth panel embodiment of the system illustrated in FIG. 4.
FIG. 9 is a representative veneer system according to an embodiment
of the invention, which provides for seamless corners.
DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION
Reference will now be made in detail to various exemplary
embodiments of the invention. The following detailed description is
presented for the purpose of describing certain embodiments in
detail and is, thus, not to be considered as limiting the invention
to the embodiments described. More particularly, specific
embodiments of the invention are described in reference to the
drawings, however, it will be noted that the embodiments provided
do not need to contain all elements described and can be combined
with individual features of other embodiments described in this
specification.
FIG. 1 provides a schematic diagram showing installation of a
veneer system 130 according to the invention. This system, and any
system or panel described in this specification, can be installed
with or without mortar. One advantage of the systems of the
invention is that mortar is not required, but can be optional for
additional support, strength, or longevity of the overall system.
As shown in FIG. 1, each panel 100 of this embodiment once
installed on a surface resists pullout of the panel and adjacent
panels by engaging or overlapping one or more adjacent panels along
the panel itself or along their suspension rails, or a combination
thereof. In this embodiment, the panels are installed on a wall
surface by inserting screws 190 through v-shaped grooves 123 in the
hanging brackets. Preferably, as shown, each panel comprises
engagement surfaces for engaging at least three sides of the panel
with at least three adjacent panels in the system. The overlapping
surfaces can be any combination of one or more surfaces of the
panel itself or one or more surfaces of a bracket installed in the
panel. More particularly, each panel in this embodiment has a
vertical engagement surface 115, 116 (not shown) that overlaps with
the vertical engagement surface of an adjacent panel. Each panel
also has a horizontal engaging surface 115, 116 for overlapping
with a horizontal surface of another panel in the system. The
hanging bracket(s) provide two additional horizontal engagement
surfaces 128, 129 for interacting with horizontal surfaces of other
panels in the system. In this embodiment, the suspension rails are
considered universal in that they can be incorporated into either
the upper part or lower part of the tile and provide the same
function. Preferred embodiments have four engaging surfaces on the
panels themselves, such as on both vertical and both horizontal
edges, and two additional engagement surfaces provided by the
suspension rails.
In this manner, there are four surfaces along three sides of each
panel that engage other panels upon an attempt to pull the panel
out of the installed system. These four engaging surfaces cooperate
to resist pull out of the panel from the veneer system. For square
panels, the total length of the engaging surfaces would be about
90% or more of the perimeter of the face of the panel. For
rectangular panels, the engaging length would be greater than 100%
of the perimeter when the engagement surfaces of the hanging
bracket are disposed along the longer sides as shown. Any amount of
overlap between panels and/or their support brackets will provide
resistance against pullout from the system. Preferred are panels
having means for resisting pullout along two or more sides of the
panel, especially one horizontal and one vertical side.
It is further important to note that when the panels are stacked in
a typical offset manner with respect to one another, as shown in
FIG. 1, resistance to pullout of one panel is distributed among all
panels that abut the panel being pulled out. As force is exerted on
a panel to pull it away from the wall, the panel engages with the
two tiles immediately above due to the overlapping faces of the
panels. As the panels immediately above the panel of interest begin
to move away from the wall, those panels engage the panel of
interest as well as the panels to the left and right of the panel
of interest by way of the overlapping upper support brackets. As
the panels to the left and right of the panel of interest are
pulled away from the wall, the panels immediately below them and
below the panel of interest are engaged by way of their lower
support brackets. It is important to note that when referring to
upper and lower support brackets in this specification it is also
meant to include a single support bracket with upper and lower
engagement surfaces. Although resistance to pullout from all
abutting panels is not required for all embodiments of the
invention, the strength of the system is increased by distributing
the resistance to pullout among all of the abutting panels.
FIGS. 2A-E are respectively top and bottom planar views, a side
elevation view, and top and bottom perspective views of an
exemplary panel 200 of the invention. These panels can be installed
in a veneer system using conventional mortar, adhesive, or screws.
For additional resistance against pullout, hanging bracket(s) fixed
or incorporated into the back of the panel can alternatively or
additionally be used. As shown in FIG. 2A, the panel can be
constructed of a light weight concrete product molded to form a
locking stone veneer. The "locking" feature of this stone
embodiment is a stepped surface 216. What is meant by locking
according to this specification is that the structure is capable of
overlapping with structure of an adjacent panel such that
resistance is provided by the second panel against pullout of the
first panel from the system. More particularly, the stone comprises
a square face (but can be any shape) that is a planar surface with
four sides and with or without beveled edges. A second planar
surface is stepped a selected distance below the face and appears
along two sides of the stone. In essence, the panel appears to
comprise two identical shaped tiles stacked one on top of the other
in an offset manner to provide two stepped surfaces 216. When
installed in a panel system according to the invention, such a
stone would be capable of engaging two other stones abutting the
two sides of this stone along the exposed stepped surface area.
What is meant by engaging according to this specification is that,
when installed, the stepped surface 216 or any engagement surface
of the panel or its bracket will resist against pullout of this
stone or another stone from a veneer system according to the
invention. Once installed, the back side of the top horizontal
stepped surface 216 of this stone can be disposed in the panel
system in a manner that provides this stone overlapping and in
contact with a corresponding surface of a stone placed above this
stone. Likewise, the back side of the side vertical stepped surface
of this stone can be disposed in the panel system in a manner that
provides this stone overlapping and in contact with a corresponding
surface of a stone placed to the side of this stone. In this manner
this stone will prevent pullout of the stone(s) above it and the
stone(s) to the side of it due to the overlapping engagement
surfaces.
The size of the stone panels is not critical. Preferred embodiments
comprise small panels having a face that measures about 4 inches by
about 8 inches, or a about a 0.22 sq. ft. face. A typical large
size stone could have a face that measures about 101/4 inches by
about 123/4 inches, or about a 0.91 sq. ft. face. Other stones
could measure about 4 inches by about 171/2 inches or with a 0.49
sq. ft. face, or about 4 inches by about 83/4 inches, or about a
0.24 sq. ft. face. Indeed, these shapes and sizes are meant to be
exemplary rather than limiting and any shape or size panel can be
used according to the invention. Similarly, any shape panel can
also be used, including for example, square, rectangular,
triangular, octagon, etc. shaped panels.
Further, any material can be used to manufacture the panels,
including plastic, rubber, wood, stone, metal, glass, cement,
ceramic, porcelain, or composite materials. A preferred stone-like
material that is light weight can be manufactured from a
combination of cement, aggregate, pigments, and admixes. Preferred
materials are easy to mold into a desired shape or size and are of
a consistency to allow for ease of embedding the support brackets
into the material.
FIG. 2B is a bottom plan view of the panel 200 shown in FIG. 2A.
The bottom (or underside) of the stone also has a planar face and a
planar stepped surface 216 along the other two sides of the stone.
The planar face of the stepped surface 216 on the underside of the
stone, once installed, will act to prevent a stone placed
vertically below this stone and a stone placed horizontally to the
left of this stone from being withdrawn from the system. In
essence, the stepped planar surfaces 216 on the top and bottom
faces of the stone are capable of interlocking with the stones
abutting this stone on all four sides of the stone. More
particularly, the two planar stepped surfaces 216 viewable from the
top provide resistance against removal of the stone from the
system, while the two stepped planar surfaces 216 viewable from the
bottom of the stone counteract removal of other stones adjacent to
this stone in the system.
It is noted that for convenience only the orientations given in
this specification, including top, bottom, above, below, right,
left, vertical, and horizontal refer to viewing the system in its
final installed form, in which the system is viewed from the front.
Thus, to eliminate any confusion, when viewing the system from the
back side of a panel 200 (as in FIG. 2B), the structure appearing
on the right-hand side of the drawing is in essence the structure
that would appear on the left-hand side of an installed system when
viewing the face of such an installed system.
In preferred embodiments, the total length of all four stepped
planar surfaces 216 totals more than 50% of the perimeter of the
stone. In this embodiment, the top face of the stone is 41/8 inches
square with a perimeter of about 161/2 inches. The bottom face of
the stone is slightly smaller at 4 1/16 inches square with a
perimeter of about 161/4 inches. The two stepped surfaces 216 of
the top face are 41/8 inches in length and the two stepped surfaces
216 of the bottom face are 4 1/16 inches in length. The total
length of the stepped surfaces 216 is about 163/8 inches. This
corresponds with being about 99% of the length of the perimeter of
the top face.
FIG. 2C shows a side elevation view of the panel 200 of FIGS. 2A-B,
FIG. 2D shows a top perspective view, and FIG. 2E is a bottom
perspective view. As shown in these figures, the stone in this
configuration appears to have a top stone that provides the top
face of the tile and a bottom stone that provides the bottom face
of the tile, where the two stones are stacked slightly
eccentrically. This embodiment is molded as a single piece,
however, to obtain the two stepped surfaces 216, which are produced
from the off center stacked-stone appearance.
FIGS. 3A-C provide various views of a hanger embodiment according
to the invention. Provided by this embodiment is a preferred
suspension rail 320 comprising: an elongated planar member 321 with
upper and lower longitudinal edges 326; upper and lower c-shaped
channels 325 and 327 disposed along and formed in part by the
longitudinal edges 326 of the planar member; one or more feet 322
in communication with the planar member 321 or c-shaped channel 325
or 327 and disposed perpendicular thereto; a v-shaped groove 323
disposed lengthwise along and in communication with the upper
c-shaped channel 325; an upper planar mounting bar 328 disposed
lengthwise along and in communication with the v-shaped groove 323
and parallel to the planar member 321; and a lower planar mounting
bar 329 disposed lengthwise along and in communication with the
lower c-shaped channel 327 and disposed at an angle in the range of
about 135-180 degrees relative to the planar member 321.
A dual extrusion suspension rail 320 (used interchangeably with
bracket or hanger or rail) for incorporating (eg, molding or
forming) into each panel of the veneer system. As shown in FIG. 3A,
the suspension rail 320 has a low profile planar body with
protrusions or feet 322 extending from the body about perpendicular
thereto. These protrusions or otherwise referred to as feet 322
facilitate embedding of the bracket into a material to be molded
into a desired shape (ie, panel). Here, there are two feet 322 each
of which comprises structure for preventing or resisting removal of
the feet 322 from the panel material once cast or molded. These
protrusions are integral to the body and in this embodiment made of
the same plastic material as the body. The protrusions extend
lengthwise along the body and can be molded into the panels of the
invention to provide a panel with hanger that will resist pull out
from the panel and not break free from the panel. Other means for
securing the hanger to the panel can be used, such as posts instead
of lengthwise planar elements, however, the more material of the
hanger that is molded into the panel the more secure the hanger
will be within the panel. Here, two feet 322 are provided, but any
number can be used.
FIG. 3B shows the back face of the hanger, which comprises one or
more grooves in the plastic material along the length of the
bracket to provide flexibility in positioning of the engagement
arms of the bracket. Any means for incorporating flexibility into
the suspension rail 320 can be used, including using a plastic or
metal material for the suspension rail body that is flexible enough
to bend into a desired shape or has flexibility that allows for
temporary bending of the suspension rail 320. Such flexibility is
advantageous to allow for some variability in the positioning of
the panel into a facade system during installation. As shown,
another means for allowing some movement of the mounting bars 328
and 329 relative to the planar member 321 can be provided by the
c-shaped channels 325 and 327 that extend lengthwise along the
edges of the planar member 321.
With respect to the two elongated engagement arms (mounting bars)
328 and 329, these arms can be configured such that the bottom
surface of one arm is capable of overlapping with the top surface
of the other arm on a different bracket. When embedded in a
manufactured stone, the universal brackets can be disposed in a
manner to provide the elongated engagement arms 328 and 329 along
the horizontal length of the stone at the top and bottom of the
stone, or any part thereof. The engagement arms or mounting bars
328 and 329 need not be as long as the length of the panel to which
they are connected, however, the greater the length of the
suspension rail 320, the greater the strength of the system.
The bottom arm 329 of the bracket is capable of engaging or
overlapping with the top arm 328 of another bracket of a panel
disposed immediately below the panel being placed into the system.
The surfaces that engage one another are the surface of the bottom
arm 329 of a first panel that faces the panel and the surface of
the top arm of another panel that faces away from the panel.
Engagement in the context of this specification refers to
overlapping surfaces and the surfaces need not physically be in
contact with one another upon installation, however, a more stable
facade system will result if there is an interference fit between
engagement arms of the panels. Both engagement arms 328 and 329 are
disposed in approximately the same orientation with respect to the
stone. In preferred embodiments, the upper engagement arm 328 is
disposed in a plane parallel to the planar member or body 321 of
the suspension rail 320, while the lower mounting bar 329 is angled
slightly toward the planar member 321. For example, the lower
mounting bar 329 can be fixed at an angle relative to the planar
member, such as approximately in the range of 135-180 degrees away
from the top surface of the planar member. With the lower mounting
bar 329 at a slight angle relative to the planar member 321 and
thus relative to the upper mounting bar 328, insertion of that
panel into the facade system is facilitated in that the lower
engagement arm 329 can be inserted behind the upper engagement arm
328 of another panel immediately below the panel being installed
and engagement of the two surfaces will be automatic due to the
angle of the lower mounting arm 329.
Engagement of the engaging arms of the bracket(s) is also shown in
FIG. 1. In some embodiments, the mounting bars in combination with
the panel can provide four surfaces for engagement to resist pull
out of the panel or adjacent panels away from the wall to which
they are attached.
FIG. 3C shows the embedding feet 322 disposed lengthwise along the
rail 320. As is further shown, structure can be incorporated into
the lengthwise protrusions (ie, feet) 322 to provide additional
pull out resistance, such as opposing hooks or directionally
opposed hooks as shown. Another feature of the bracket is the
V-shaped cut out 323. This provides a position for a screw or other
securing means to be positioned when fastening the panel to the
wall. For example, once a panel is positioned into a desired place
within the veneer system, a screw can be used in combination with
the V-shaped cut out to secure the stone panel to the face of the
wall and provide the head of the screw in a recessed position with
respect to the bracket. The advantages of such a system should be
immediately apparent in that the panels can be secured quickly and
easily to the wall and interlocked with one another to provide a
strong veneer system without the need for mortar.
Other rail configurations are also included within the scope of the
invention. Preferred are universal brackets that can be installed
along any side of a panel without requiring a side-specific
configuration. A universal bracket is smaller and requires less
plastic material. Ideally, the universal bracket comprises two
surfaces capable of engaging corresponding surfaces of another
bracket of the same type, although only one engagement surface of
the bracket is actually used to engage a similar surface of another
panel. In other words, two universal brackets would be used for
each panel as opposed to the single bracket described in FIGS.
3A-C. The base of the bracket can comprise at least two feet for
facilitating the embedding of the bracket into a material to be
molded into a desired shape. Here, there are two feet each of which
comprises structure for preventing or resisting removal of the feet
from the panel material once cast or molded. Another feature of the
brackets is the two elongated engagement arms. The engagement arms
are configured such that the bottom surface of one arm is capable
of overlapping with the top surface of the other arm on a different
bracket. With two pieces needed to accomplish the same function as
the single piece bracket described above, manufacturing of the
stone panels may be slightly more complex as placement of two
brackets instead of one is required. Non-universal brackets can
also be used, however, cost of manufacturing and complexity of the
configurations may be unnecessarily increased.
Specific universal brackets can include brackets measuring about 2
inches by about 51/2 inches for equipping a rectangular shaped
extruded panel that measures about 11 inches long and 51/2 inches
wide. Again, it is not critical the size, shape, or material of any
panel or bracket of the invention and dimensions and materials can
be altered according to desired needs. The bracket(s) can be
embedded in the panels during manufacturing in such a manner to
dispose the brackets on the rear face of the panel. Although any
number of brackets can be used to support a particular panel, such
as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, and so on (limited only by the
size of the panel and the size of the brackets), ideally two
universal brackets are used (one at each of opposing sides of the
panel) and are disposed along the entire length of the panel.
For example, one bracket measuring about 5.5 inches long could be
positioned and embedded in one end of the panel that measures about
5.5 inches long. A second bracket (universal, i.e., of the same
configuration as the first bracket) could be embedded at the
opposing end of the panel that measures about 5.5 inches long. Such
a panel would then be inserted into the veneer system with the
shorter 5.5 inch sides disposed horizontally to enable the brackets
of the panel to engage with the panels adjacent to it and disposed
above and below the panel in the system.
Alternatively, one or two brackets could be disposed and embedded
in the panel along the 11 inch sides of the panel. In this case,
one bracket could be installed at each side (leaving about half the
length of the 11-inch sides unsupported with a bracket) or two
brackets could be disposed side by side along each 11-inch side so
that the entire or substantially the entire length of each 11-inch
side is supported by brackets. A panel operably configured in this
manner would then be installed into the veneer system so that the
11-inch sides were horizontal.
Using smaller universal brackets in this way further increases ease
of manufacturing in that the brackets can be used both for smaller
and larger panels. More specifically, for example, two 5.5 inch
brackets could be used on opposing sides of a square panel
measuring about 5.5 inches on each side, or two or four 5.5 inch
brackets could be used on an 11-inch side of a rectangular panel
(as just described).
Yet another bracket embodiment can comprise engaging arms
configured to be about the same length and width and disposed in
parallel, adjacent or abutting horizontal planes. It is not
critical the degree to which the planes in which the engaging arms
lie are adjacent or if they abut one another, but it is important
to note that the closer the clearance between the two, the tighter
the fit between panels of the system and the less movement of the
panels will be experienced post-installation.
An alternative embodiment of a bracket according to the invention
includes another single piece rail. Incorporated into its
configuration are the engaging arms, only just one bracket is
needed instead of two to provide the corresponding top and bottom
engaging arms disposed along the length of the panel at the top and
bottom of the back portion of the panel. In this embodiment the
base or body of the bracket hanger comprises at least two feet for
facilitating the embedding of the bracket into a material to be
molded into a desired shape. Here, there are four such feet each of
which comprises structure for preventing or resisting removal of
the feet from the panel material once cast or molded. The structure
for resisting removal of the feet from the molded panel in this
embodiment comprises a hook at the end of each foot. Here, the
hooks are oriented in the same direction, but can be oriented in
different directions as well. Another feature of the brackets is
the two elongated engagement arms. The engagement arms are
configured such that the bottom surface of one arm is capable of
overlapping with the top surface of the other arm on a different
bracket. When embedded in a manufactured stone, the brackets are
disposed along the horizontal length of the stone at the top and
bottom of the stone. Both brackets are disposed in the same
orientation with respect to the stone. As shown, the bottom arm of
the bottom bracket is capable of engaging or overlapping with the
top arm of a top bracket of a panel disposed immediately below the
panel being placed into the system. The surfaces that engage one
another are the surface of the bottom arm of the bottom bracket (of
a first panel) that faces the panel and the surface of the top arm
of the top bracket (of another panel) that faces away from the
panel.
Other embodiments of the invention include a veneer system for
posts or columns. Preferred embodiments include a panel facade
system 430 (see FIGS. 4 and 5A-B) comprising: a plurality of facade
panels 400, 500 each having a front face 410, 510 for forming part
of a first facade, wherein the face is formed as a plurality of
stacked stones and has a concave rectilinear polygonal outline
configured for mating with adjacent panels when installed in the
system; a back side 412, 512 with a suspension rail 420, 520 in
communication therewith; and left and right sides 411 511 for
forming part of another facade in a different plane. Such panel
facade systems can comprise a group panels the combination of which
is shaped to tessellate a surface that wraps around a 270 degree
corner or that wraps around a 90 degree corner or both. What is
meant by tessellate according to this specification is that the
panel shapes fit together like a puzzle, whether on a planar
surface or a combination of planar surfaces and corners, to form a
facade with an annular-like rectangle or square configuration,
meaning the surface of the facade is disposed in four planes
perpendicular to one another. The panel facade systems preferably
comprise a number of panels in which at least three of the panels
have different front face outlines chosen from z-shaped 800,
t-shaped 600, and inverted t-shape 700 outlines (see FIGS. 6, 7,
and 8). The panels preferably in combination with each other are
shaped to tessellate a surface that wraps around a post. Likewise,
the panel shapes can be grouped to tessellate the interior surface
of a room, such as around the base of a ceiling as crown molding,
if desired.
FIG. 4 shows a perspective view of a 4-panel system for covering
the sides of a post. As shown, rows of four panels around the
circumference of the post can be arranged and stacked on top of
previous rows until a desired amount of the post is covered. More
specifically, four specifically shaped panels can be installed
along four corresponding faces of a post. The four panel pieces are
configured to cooperate with one another to interlock around the
circumference of the post. Here, a cross section of the post is
square, but any shape post can be used and appropriate sized panels
selected for a particular design. The outline of the face of the
panel pieces is preferably shaped in the form of a concave
rectilinear polygon. In this manner the panels fit together like
puzzle pieces so that the outline of each panel is difficult to
determine upon visual inspection of the installed facade. Further
camouflaging the joints between panels is the stacked stone
appearance of the face of the panel. Due to the panel being divided
up to look like a collection of several smaller stones, it is
difficult to determine where the outline of the panel starts and
stops. No other existing modular facade system provides this
benefit.
On the interior face 412, 512 of each panel 400, 500 (back side or
side installed on post) there is provided a hanger or bracket
according to the invention. Any of the suspension rails 420, 520
described in this specification can be used, whether single piece
or universal. The hanger or rail is preferably a single piece and
universal that can be incorporated into the panel during
manufacture of the panel or attached to the panel prior to
installation. Alternatively, no brackets can be used and the panels
can be installed on a post or wall corner using mortar. As shown,
the hanger extends an amount above the panel in which it is
embedded to provide for interlocking of the panels in the system by
providing a surface for engaging with the hanger of another panel
disposed on top. In this manner, each panel can be secured into the
system by interlocking with a panel above and below. The
bottom-most panel can be secured onto the post initially with a
securing rail that provides an engagement surface for that panel's
hanger. Alternatively or in addition, as with any embodiment of the
invention, mortar, adhesive, or other securing means such as screws
can be used. In preferred embodiments, a v-shaped groove is
provided in which screws can be inserted at any point along the
length of the suspension rail for hanging the bracket and panel to
a surface. The v-shaped groove can further comprise structure (such
as a groove) for supporting the head of screws and maintaining the
screws in a certain position within the v-shaped receiving
groove.
As shown, the finished product is especially advantageous because
the modular nature of the system is not readily apparent. It has
been found that panels comprising three or more "stones" on the
face and where some of the stones are in a staggered configuration
to one another provide a visually pleasing veneer system in that
the outline of each panel is difficult if not impossible to detect
by passersby.
Panels for providing a veneer to posts and columns according to the
invention need not be of any specific shape or size and such will
depend greatly on the particular application for which the panels
are used. For example, when covering a post that is 4-inches
square, the panels should be greater than 4-inches wide, such that
the entire face of each side of the post may be completely covered
by a panel. Further, it is preferred that each panel have finished
"stone" that is visible from more than one side of the post.
Especially preferred are panels that are visible from three sides
of the post.
As shown in FIGS. 5A-B, 6A-B, 7A-B, and 8A-B the four panels
constituting one row around the post have a specific interlocking
configuration. Though the panels may differ in shape, each panel
has three faces, such that the panel can be seen on three sides of
a finished post, or in three of the facades of the post. More
particularly, when installed as a veneer to a post, each panel has
a first main face and two minor faces. The main face of the panel
constitutes the majority of the surface area of one side of the
post, while the two minor faces protrude into the surface area of a
panel on adjacent sides of the post, such as the left and right
sides of the post. In this manner, the individual panels of the
finished post veneer system cannot be detected upon mere visual
inspection. Such a panel system differs from existing modular
corner covering systems in that each panel has an overall block or
brick shape as opposed to the typical L-shaped configuration, which
allows for the panel to be seen on another side of the post or
corner joint of two walls. L-shaped panels are difficult to
manufacture and are susceptible to breakage during shipping,
installation, or other handling of the panel pieces due to their
awkward, non-stackable shape. In contrast, panels of the invention
can easily be stacked prior to shipping or installation. No other
existing panel system comprises substantially planar panels with
three faces that can be used for covering a flat wall surface, a
concave corner surface, and a convex corner surface. Existing
corner covering systems comprise a combination of planar panels and
a variety of L-shaped panels to accomplish this goal. In contrast,
the panels of the invention are universal in that they can be used
to cover any surface.
As shown in FIGS. 5A-B, 6A-B, 7A-B, and 8A-B the four panels
constituting one row around the post have a specific interlocking
configuration. Though the panels may differ in shape, each panel
has three faces, such that the panel can be seen on three sides of
a finished post, or in three of the facades of the post. More
particularly, when installed as a veneer to a post, each panel has
a first main face 410, 510 and two minor faces 411, 511. The main
face 410, 510 of the panel constitutes the majority of the surface
area of one side of the post, while the two minor faces 411, 511
protrude into the surface area of a panel on adjacent sides of the
post, such as the left and right sides 411, 511 of the post. In
this manner, the individual panels of the finished post veneer
system cannot be detected upon mere visual inspection. Such a panel
system 430 differs from existing modular corner covering systems in
that each panel 400, 500, 600, 700, 800 has an overall block or
brick shape as opposed to the typical L-shaped configuration, which
allows for the panel to be seen on another side of the post or
corner joint of two walls. L-shaped panels are difficult to
manufacture and are susceptible to breakage during shipping,
installation, or other handling of the panel pieces due to their
awkward, non-stackable shape. In contrast, panels of the invention
can easily be stacked prior to shipping or installation. No other
existing panel system comprises substantially planar panels with
three faces that can be used for covering a flat wall surface, a
concave corner surface, and a convex corner surface. Existing
corner covering systems comprise a combination of planar panels and
a variety of L-shaped panels to accomplish this goal. In contrast,
the panels of the invention are universal in that they can be used
to cover any surface.
Provided in FIGS. 5A-B is a first panel 500 of the panel veneer
system for covering posts according to an embodiment of the
invention. Respectively, are front and back schematic diagrams of
the proximal panel shown in FIG. 4. This proximal panel shows
"stones" formed on the face of the panel in a staggered or offset
configuration and stacked at least 3-4 stones high and at least 2
stones wide. The outline of the panel face is generally a z-shape
polygon to provide three finished faces to the panel, a
configuration that fits with other specifically shaped pieces,
namely the t-shaped and inverted t-shaped panels, and to hide the
overall outline of the panel when installed in the system. The
stones can be molded or carved into the panel and as such are not
actually discrete stones but merely give the appearance of being
discrete stones. Panels 500 can also comprise a collection of
discrete stones joined together by mortar or an adhesive, but such
embodiments may have a reduced strength and are more complex from a
manufacturing perspective and so are less preferred. Any number of
"stones" or formations in the panel giving the appearance of
individual dry stacked stones or individual stones joined together
with mortar can be used. If the panel constitutes one stone, then
it will be easier for observers of the facade to detect the outline
of the individual panels and to identify the work as a modular
system instead of the more desirable conventional brick and mortar
look.
The inventors have found that panels 500 comprising the formation
of a plurality of stones with at least two stones disposed in an
offset manner relative to one another are preferred. For example,
the panels can comprise only two stones, where the stones are
stacked on top of one another in an offset manner. In such a
configuration the panel is said to comprise two stones high and one
stone wide. Further preferred are panels with at least three stones
stacked high, wherein at least one of the stones is offset from
another. What is meant by "offset" in the context of this
specification is that where two stones abut, the abutting edge of
at least one of the stones is not fully abutted by the abutting
edge of the other stone. For example, an offset configuration can
simply be achieved by having one stone with a first length and a
second stone with a smaller length stacked immediately above or
below the first, such that the longitudinal edges of the smaller
stone do not line up with the longitudinal edges of the larger
stone.
Another feature of embodiments of the invention is a modular facade
panel comprising a front face 410, 510 formed as a plurality of
stacked stones and a back side comprising a suspension rail,
wherein an outline of the front face is a concave rectilinear
polygon. Panels with this shape render the panel universal for any
surface due to having three finished sides. As shown in FIGS. 5A-B,
the left and right edges 511 of the facade panel 500 are staggered
or offset to allow for the stones of this panel to protrude into
the face of the facade on the left and right sides of the post or
wall to which the panels are attached. In this manner, it is
difficult to detect where the outline of each panel is thereby
minimizing any negative aesthetic impact produced by the system
upon installation. This configuration also allows for greater
security of the panels within the system, as there are additional
surfaces for engaging surfaces of other panels of the system to
prevent movement of the panels once installed. These panels are
universal in that they can be used to cover the planar surface of a
wall whether or not a corner is being covered. Additionally, the
panels can be applied to 90 degree corners (concave) or 270 degree
corners (convex), without the need for special corner-specific
panel pieces in the facade system.
As shown, each panel 500 in the system can also have a stepped
configuration for providing additional engagement surfaces for
securing the panels in the system. FIG. 5B shows a recessed surface
515 along most of the length of the bottom side 514 of the back of
the panel. The recess 515 of this panel 500 can then be positioned
in the system above a panel having a corresponding protrusion 516
along its top edge 513, as shown in FIG. 5A. (A similar protrusion
416 is also shown in FIG. 4). As shown in FIG. 5A, this first panel
also has a protrusion 516 on the top edge 513 of the panel 500,
which can be interlocked with a corresponding recess 515 of another
panel disposed above this panel. The protrusions 516 of the system
can be the same height and length for each panel 500 and the
recesses 515 can be the same height and depth for each panel 500 so
that any panel can be placed on top of any other panel in the
system. The recesses 515 and protrusions 516 can be made to fit
specific panels to ensure that a panel is not placed on top of an
identical panel to ensure the individual panels remain undetected
once installed in a system.
FIGS. 6A-B are schematic drawings of the front and back,
respectively, of the right panel shown in the system of FIG. 4.
This panel 600 comprises a suspension rail or hanger 620 integral
to or embedded in the panel on its back side (side that faces or is
installed on the post or wall) for interlocking with panels above
and below the panel. Also included is a protrusion 616 along the
top edge and a recess 615 along the bottom edge 614 for engaging
complementary surfaces of panels above and below this panel in the
system. The face of the panel has a staggered configuration and its
outline is basically T-shaped for extending into the face of the
facades formed by the proximal panel and the distal panel of the
system shown in FIG. 4. This right panel comprises at least 3-4
stones in height and at least 2 stones wide.
FIGS. 7A-B are front and back views, respectively, of the distal
panel of the system shown in FIG. 4. This panel 700 has the outline
of an inverted T-shape and is configured for protruding into the
face of the right and left panels installed in the system. This
distal panel comprises at least 2-3 stones high and at least 1-2
stones wide. As shown in FIG. 7B, the panel 700 can comprise
stepped surfaces for securing multiple panels in the system, such
as protrusion 716 and recess 715.
FIGS. 8A-B are views of the left panel of the system of FIG. 4.
This left panel 800 is at least 3-4 stones high and at least 2
stones wide. This panel is configured to be the same overall shape
and have a face with the same overall outline as the proximal
panel. In this manner, only three distinct panels need to be used
for each row of the system. The panels can be made of any
configuration so that the panels of one row interact with each
other and subsequent or previous stacked rows in the manner
described, ie, interlocking with above and below panels at the
panel face by way of protrusion 816 engaging with recess 815 of
another panel 800 and/or hangers 820 and/or protruding into the
face of adjacent panels.
Trim elements can be incorporated into the post systems of the
invention, such as trim to be disposed around the base of a post or
to top off the post to provide a finished look. Additionally, a cap
stone can also be incorporated into the systems.
Embodiments of the invention provide a mortarless veneer system
comprising: a plurality of panels for forming a facade on a
substrate surface, wherein each panel comprises means disposed
along two adjacent sides of the panel for resisting its removal
from the facade and means disposed along two other adjacent sides
of the panel for resisting removal of adjacent panels from the
facade, and wherein each panel comprises at least one universal
bracket, or a combination of two or more universal brackets,
embedded in or otherwise integral to the panel, wherein the bracket
or brackets together provide structure disposed along two opposing
sides of the panel for resisting its removal from the facade.
Additionally, embodiments provide a mortarless veneer system
comprising: a plurality of panels capable of interlocking with one
another to form a facade on a substrate surface, wherein each panel
is operably configured to comprise at least four planar surfaces
for resisting its removal from the facade, and wherein each panel
is operably configured to comprise at least four additional planar
surfaces for resisting removal of adjacent panels from the
facade.
Substrate covering systems are also included within the scope of
the invention, including facade and veneer systems for walls and
ceilings or any other planar surface of interest. Preferred
embodiments include a wall covering system comprising: a plurality
of panels for forming a facade on a wall, each having a front face
with a perimeter of a selected length, wherein each panel has
surfaces along its perimeter for engaging, in response to force,
adjacent panels in the facade and the surfaces have a combined
length of at least 50% or more of the length of the perimeter.
Also included in specific embodiments of the invention is a wall
covering system comprising: a plurality of panels for forming a
facade on a wall, each having a front face and a perimeter around
the front face of a selected length, wherein each panel is operably
configured with at least three planar surfaces for resisting its
removal from the facade in response to force by engaging with at
least two adjacent panels in the facade, and wherein the engaging
surfaces have a combined length that is between 50% and 150% of the
length of the perimeter.
Veneer systems comprising a plurality of panels each having a top
face with a selected perimeter length; wherein each panel has a
stepped surface configuration around its perimeter; such that, upon
application of a pullout force applied to a panel: a) two of the
stepped surfaces are capable of resisting removal of the panel by
engaging with two adjacent panels in the facade; and b) two of the
stepped surfaces provide pullout resistance for adjacent panels in
the facade, are further embodiments.
Further embodiments include a veneer system comprising a plurality
of panels each having a stepped top and bottom surface
configuration and at least one universal bracket embedded in or
otherwise integral to the panel, which, when installed as a facade
and a central panel is surrounded on all sides by adjacent panels
in the facade, all of the adjacent panels are capable of providing
resistance to removal of the central panel due to the configuration
of the stepped surfaces and the universal brackets. Even further
embodiments include a wall veneer system comprising a plurality of
panels having a top face with a perimeter of a selected length and
operably configured, such that when installed on a wall, each panel
adjacent to a central panel is capable of providing pullout
resistance to the central panel along surfaces with a combined
length that is about 90% or greater than the perimeter of the panel
face.
FIG. 9 shows a panel system 930 of the invention as installed on
the corner of a wall surface. In this embodiment, the panels are
installed on a wall surface by inserting screws 990 through
v-shaped grooves 923 in the suspension rails. In this embodiment
the panels 900 can be installed using suspension rails 920 of the
invention and/or mortar. A mortarless system is shown in FIG. 9,
which provides a close-up perspective view of a facade system
applied to two planar surfaces and an intervening convex corner.
Similar to the post system, the wall system in this configuration
comprises panels 900 with the inventive hangers imbedded in the
back side of the panel. Further security against pull out is
provided by a protrusion and corresponding recess on the top and
bottom edges of the panel for interlocking the panel surfaces with
panel surfaces above and below each panel. The face of the panels
is configured to have "stones" protruding into the face of an
adjacent panel on the corner so as to make it more difficult for
determining the outline of each panel and disguise the modularity
of the system. The shape of the panels is such that the panels are
combined in a manner to fit together to completely cover the wall
and corner surfaces without the overall outline of each panel being
detected.
Chair rail embodiments are encompassed by the invention as well.
Some embodiments can include a suspension rail for attaching the
chair rail to a wall and within a facade system according to the
invention. More particularly, the chair rail can be used to top off
a wall system at any point along the surface of the wall. A hanger
can be incorporated into the chair rail for installation. For
example, the chair rail can be positioned along the top of the wall
panel veneer system and rest thereon. Then the hanger can be
secured to the wall with screws.
Modular fireplace stone surround systems are also included within
the scope of this invention. The product components are provided in
a system in which the product can be fitted to any height and width
fireplace easily, conveniently, and without requiring further
finishing of the stone. For example, the top of the fireplace
surround can be provided in three or more component parts. A center
diamond piece can be positioned on the wall in the desired location
and attached thereto with the bracket incorporated therewith. Then
the stones to be positioned along the length of the top of the
fireplace can be cut to the desired length to fit the width of the
fireplace. The cut ends of the stone are then placed adjacent the
center diamond so that the unfinished ends are hidden by abutting
up against a side face of the diamond. The finished ends of the
stone (the uncut end) can then be positioned outwardly. Side
surrounds to be placed vertically along the sides of the face of
the fireplace can be provided as two components, a finished base
and a length of material that can be cut to the appropriate size.
In this manner, the cut end of the stone can be placed in a
position abutting the horizontal portion of the surround so that no
unfinished ends are outwardly facing.
Additional embodiments include a structural support system for
securing the panels to a wall, which includes holes in the
horizontal support members to allow for the drainage of any fluid
that may seep in between the veneer and the wall to which the
veneer is attached. The brackets embedded in the panels can be
secured to the vertical supports of this structural support system
to allow for additional ventilation and/or drainage between the
wall and the veneer.
The present invention has been described with reference to
particular embodiments having various features. It will be apparent
to those skilled in the art that various modifications and
variations can be made in the practice of the present invention
without departing from the scope or spirit of the invention. One
skilled in the art will recognize that these features may be used
singularly or in any combination based on the requirements and
specifications of a given application or design. Other embodiments
of the invention will be apparent to those skilled in the art from
consideration of the specification and practice of the invention.
The description of the invention provided is merely exemplary in
nature and, thus, variations that do not depart from the essence of
the invention are intended to be within the scope of the
invention.
The manner of use and operation of the present invention should be
apparent from the above description. It is to be realized that the
optimum dimensional relationships for the parts of the invention,
to include variations in size materials, shape, form, function and
manner of operation, assembly and use, are deemed readily apparent
and obvious to one skilled in the art, and all equivalent
relationships to those illustrated in the drawings and described in
the specification are intended to be encompassed by the present
invention.
Therefore, the present invention is well adapted to attain the ends
and advantages mentioned as well as those that are inherent
therein. The particular embodiments disclosed above are
illustrative only, as the present invention may be modified and
practiced in different but equivalent manners apparent to those
skilled in the art having the benefit of the teachings herein. No
limitations are intended to the details of construction or design
herein shown. It is therefore evident that the particular
illustrative embodiments disclosed above may be altered or modified
and all such variations are considered within the scope and spirit
of the present invention. While embodiments of the invention are
described in terms of "comprising," "containing," or "including"
various components or steps, the compositions and methods can also
"consist essentially of" or "consist of" the various components and
steps. All numbers and ranges disclosed above may vary by some
amount. Whenever a numerical range with a lower limit and an upper
limit is disclosed, any number and any included range falling
within the range is specifically disclosed. In particular, every
range of values (of the form, "from about a to about b," or,
equivalently, "from approximately a to b," or, equivalently, "from
approximately a-b") disclosed herein is to be understood to set
forth every number and range encompassed within the broader range
of values. Moreover, the indefinite articles "a" or "an," as used
in the claims, are defined herein to mean one, at least one, or
more than one of the element that it introduces. If there is any
conflict in the usages of a word or term in this specification and
one or more patent or other documents that may be incorporated
herein by reference, the definitions that are consistent with this
specification should be adopted.
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